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Original User's Manual
Installation, Setup, Operation and Maintenance
Geset 121
Article number of documentation 32708732
Copyright ©, Weber Marking Systems GmbH
Version: 02.08.12 /GRN
Weber Marking Systems GmbH
Maarweg 33
D-53619 Rheinbreitbach
E-Mail: info@webermarking.de
32708732
http://www.webermarking.de
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Summary of Contents for Weber Geset 121
- Page 1 Original User’s Manual Installation, Setup, Operation and Maintenance Geset 121 Article number of documentation 32708732 Copyright ©, Weber Marking Systems GmbH Version: 02.08.12 /GRN Weber Marking Systems GmbH Maarweg 33 D-53619 Rheinbreitbach E-Mail: info@webermarking.de 32708732 http://www.webermarking.de...
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Page 3: Table Of Contents
Content 32708732 Geset 121 Table of content 1. General information ......................6 Overview ..........................6 Liability restrictions ......................6 Warranty provisions ......................6 Copyright ..........................6 Purpose and overview of the operating instructions ............7 How to use the operating instructions .................. 7 ... - Page 4 Content 32708732 Geset 121 Safety instructions ........................27 Storage conditions ......................30 5. Description of the labeling station ................. 31 Function and Field of Application of the Labeling System ..........31 Complete overview ......................31 6. Installation and initial startup ..................32 ...
- Page 5 Content 32708732 Geset 121 Daily servicing (after approximately 8 hours of operation) ............57 Weekly servicing (after approximately 40 hours of operation) ............ 58 Quarterly servicing (after approximately 500 hours of operation) ..........58 Annual servicing (after approximately 2000 hours of operation) ..........59 Inspection ..........................
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Page 6: General Information
Any and all copying, photocopying, reproduction or translation of this document or parts thereof may only be done for personal use. Without prior written approval from Weber Marking Systems GmbH, this document may not be reproduced for the sake of third parties. -
Page 7: Purpose And Overview Of The Operating Instructions
Chapter 1 General information 32708732 Geset 121 Purpose and overview of the operating instructions These operating instructions will help you get to know the system and use it properly. They contain important instructions for the user on how to use the system safely and correctly. -
Page 8: Service-Hotline
Chapter 1 General information 32708732 Geset 121 Service-Hotline The technical service hotline is available 24 hours a day, Monday through Friday. In emergencies, parts may be shipped as late as approximately 10:00 p.m. Tel : +49 (0)2224 - 7708 - 440... -
Page 9: Explanation Of The Terms Used
Chapter 1 General information 32708732 Geset 121 Explanation of the terms used Term Explanation Is used for labeling around of round products. 3-roll system Adhesive strings Glue that has leaked out at the edge of the label can hold the label to the backing paper. - Page 10 Chapter 1 General information 32708732 Geset 121 Term Explanation Default All basis settings for the system after it is made that can differ from the status after the system is started up. The software parameters can be returned to the defaults by being reset, and any changed values are lost.
- Page 11 Chapter 1 General information 32708732 Geset 121 Term Explanation Label sensor An optical sensor that determines the gap between the labels Dictates the label format: Width x length (in the direction of Label size feed of the label liner measured in millimeters [mm]...
- Page 12 Chapter 1 General information 32708732 Geset 121 Term Explanation Product Detector A sensor for detecting the product. Most frequently, optical sensors are used (photocells, light barriers, reflective sensors). American unit of measure for compressed air. (1 PSI = 0.06895 bar).
- Page 13 Chapter 1 General information 32708732 Geset 121 Term Explanation Tamp-on Application mode in which the tamp takes a printed label by means of a vacuum, conveys it to the product and presses it on to the product. Product Delay An adjustable delay between the time at which the product is detected to the start of the dispensing cycle.
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Page 14: Safety Regulations
Chapter 2 Safety regulations 32708732 Geset 121 2. Safety regulations Behavior in an emergency The operating personnel must know the location of and how to use safety equipment, alarms, first aid and rescue equipment. What to do in an emergency? ... -
Page 15: Intended Use
Chapter 2 Safety regulations 32708732 Geset 121 Intended use The operational safety of the system Geset 121 is guaranteed only if it is used as intended. Intended use consists of the following … The labeling system may only be used for automatically labeling moving and stationary products. -
Page 16: Reasonably Foreseeable Misuse
Chapter 2 Safety regulations 32708732 Geset 121 Reasonably foreseeable misuse Usage different than or going beyond that specified under "Intended use" is considered unauthorized. The operator bears sole responsibility for Damage arising from improper use. Furthermore, the manufacturer assumes no liability for such use. -
Page 17: Hazards To The Labeling System
Chapter 2 Safety regulations 32708732 Geset 121 Hazards to the labeling system Fig. 2-1: Hazards to the labeling system Safety instructions Hazard from direct or indirect contact with voltage- conducting parts. DANGER TO LIFE! When individuals touch parts that conduct electricity arising from malfunctions. - Page 18 Chapter 2 Safety regulations 32708732 Geset 121 Hazard from easily flammable label material. FIRE HAZARD! The ribbon and labels are easily flammable. Potential injury from fire and smoke. - Keep away from sources of ignition and open fire. Danger of being pulled in by rotating elements DANGER OF BEING PULLED IN! Rotating elements on the labeling system.
- Page 19 Chapter 2 Safety regulations 32708732 Geset 121 Danger of injury from corners and edges. RISK OF INJURY! Scrapes and cuts can result from sharp edges and pointed corners. Always keep the work area clean. The label web has sharp edges.
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Page 20: Remaining Risks
Chapter 2 Safety regulations 32708732 Geset 121 *² Risk of injury due to light beam. RISK OF INJURY! *²Sensors or *²camera illumination may have a strong light intensity. Do not look into the source of light. *² only if system has the appropriate features. -
Page 21: Warnings On The Labeling System
Chapter 2 Safety regulations 32708732 Geset 121 Warnings on the labeling system Special hazards arising from the labeling system are identified with yellow stickers. The pictograms indicate hazards: Danger Life-threatening hazard due to electrical power Crushing hazard Entanglement hazard Danger due to hot surface... -
Page 22: Approved Persons
Chapter 2 Safety regulations 32708732 Geset 121 Approved persons Only authorized personnel may work on the labeling system. Observe minimum age permitted by law! The labeling system may only be used by persons who have been instructed in its use. -
Page 23: Personal Protective Gear
Chapter 2 Safety regulations 32708732 Geset 121 Personal Protective Gear Wear the following protective gear when working on the machine: PROTECTIVE FOOTWEAR To protect against falling parts and slipping PROTECTIVE WORK CLOTHES Protective work clothes fit snugly, tear easily, have tight-fitting sleeves and no projecting parts. -
Page 24: Protection Devices
Chapter 2 Safety regulations 32708732 Geset 121 Protection Devices Operate the system only if all safety- and protection devices are completely available and functional. Check the protection devices for its function: At first operation. At regular routine test. -
Page 25: ²Safety Switch
Chapter 2 Safety regulations 32708732 Geset 121 *² Safety switch Safety switchs are mounted at the protective cabinets and protective doors that can be opened. It is used to stop immediately the system if the protective covers or doors have been opened unintentionally. -
Page 26: Specifications
Chapter 3 Specifications 32708732 Geset 121 3. Specifications Dimensions Appr. 1517mm x 952,5mm x 1345,43mm (H x W x D in mm) Weight appr. 130 kg (without label roll) Power connection: 115 VAC / 60Hz (1~) Power consumption: max. 1 KVA Ambient temperature: 10 - 38 °C... -
Page 27: Transport
Chapter 4 Transport 32708732 Geset 121 4. Transport Delivery The labeling station is normally delivered by a haulage contractor. Check the package for any damage. If you notice anything unusual, notify the haulage contractor immediately and note it on the delivery slip. - Page 28 Chapter 4 Transport 32708732 Geset 121 The transport will be arranged by a Technician of the Bluhm Weber Group or by authorized specialists. Remove the packaging material and the transport securing devices only at the site of use, and transport the labeling system in its original packaging to the labeling site.
- Page 29 Chapter 4 Transport 32708732 Geset 121 Instruction Use the following procedure to transport each labeling system to its site of use. Step Procedure Transport the labeling system to its site of use (within 3 m). The labeling system is precisely positioned during installation by a technician from the Bluhm Weber Group.
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Page 30: Storage Conditions
Chapter 4 Transport 32708732 Geset 121 Storage conditions The conditions for storing a labeling system are the same as those of normal operation. For details see the chapter: "Specifications". Instruction Store the labeling system securely as follows Step Procedure *² Remove the label material from the system Transport the system to its storage location. -
Page 31: Description Of The Labeling Station
5. Description of the labeling station Function and Field of Application of the Labeling System The labeling station Geset 121 is used to label cylindrical products automatically. The products are fed manually or by the (customer‘s) conveying system at the infeed of the labeling station. -
Page 32: Installation And Initial Startup
Chapter 6 Installation and initial startup 32708732 Geset 121 6. Installation and initial startup Safety instructions Hazards from actively controlled movements. RISK OF INJURY FROM CRUSHING! The movements of the machine are motor-driven by an automatic controller. ̶ Maintain a distance from moving parts. -
Page 33: Installation
This required professional knowledge cannot be completely communicated by the operating instructions; therefore a technician from the Bluhm Weber Group needs to perform the installation or accept the labeling system in a final inspection. The warranty does not cover damage or consequential damage arising from improper installation lacking the necessary fine adjustments. -
Page 34: Setting Up The Labeling System
Chapter 6 Installation and initial startup 32708732 Geset 121 Setting up the labeling system Requirements The labeling system must be completely installed. The labeling system is unpacked and prepared (see the chapter: "Transportation") near the labeling site. ... -
Page 35: Connection To Supply Voltage
Chapter 6 Installation and initial startup 32708732 Geset 121 Connection to supply voltage Safety instructions Hazards from actively controlled movements. RISK OF INJURY FROM PULLING IN AND CRUSHING! Immediately after turning on, several system parts make a reference run or move to its home position! ̶... -
Page 36: ² Connecting To Compressed Air
Chapter 6 Installation and initial startup 32708732 Geset 121 *² Connecting to compressed air Safety instructions *² Danger due to compressed air. HEALTH HAZARD! Whipping compressed air hoses, thrown parts or uncontrolled moving parts can cause injury. The compressed air connection may only be connected to a compressed air supply that is secured against compressed air overstepping. - Page 37 Chapter 6 Installation and initial startup 32708732 Geset 121 Requirements Compressed air supply (KS4-CK-6 coupling) according to "Specifications" is next to the labeling site (max. 1.5 m distant). Service fittings, connecting line with a KS4-CK-6 coupling jack and pneumatic hose (see the accessories box).
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Page 38: Adjustment And Initial Operation Of Labeling System
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 7. Adjustment and initial operation of labeling system Safety instructions Hazard from actively controlled movements. RISK OF INJURY FROM CRUSHING! The applicator movements are motor-driven by an automatic controller. -
Page 39: Adjustment And Initial Operation
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Adjustment and initial operation The labeling system has to be re-adjusted at initial operation or at a product change. In following adjustment table all required working steps are listed. -
Page 40: Adjust Side Guidance
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Adjust side guidance Fig. 7-1: Side guidances Description STAR GRIP SIDE GUIDANCE OPERATOR’S SIDE SIDE GUIDANCE DISTANCE STAR GRIP SIDE GUIDANCE DRIVE SIDE The side guidances are adjusted by star grips. -
Page 41: Change Peeler Blade
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Change peeler blade Fig. 7-2: Change peeler blade Pos. Description SCREWS FOR PEELER BLADE’S BRACKET PEELER BLADE The peeler blade depend on product and label width. That is the reason why the appropriate peeler blade has to be changed according to product and label. -
Page 42: Pitch Peeler Blade (Gimbal Adjustment)
To adjust the longitudinal- and lateral inclination, the clamping screws can be easily loosened and after adjustment they can again be tightened steadily again after adjustment. This adjustment was arranged during start-up by Bluhm Weber and is not necessary during production operation. - Page 43 Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Requirements Power and compressed air supply is turned off. No transportation of products. Instruction Please adjust the height of the peeler blade as follows. Step Procedure Loosen the clamping lever slightly.
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Page 44: Insert Label Roll In Labeler
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Insert label roll in labeler Please consider that for each labeler for the respective product the right label roll is loaded. Further information on adjustment of the labelers is described separately in provided manual. -
Page 45: ²Wrap Belt (Wrap Around Labeling)
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 *²Wrap belt (Wrap around labeling) Fig. 7-4: Wrap belt Pos. Description WRAP BELT FOAM RUBBER PLATE CLAMPING TO ADJUSTMENT OF FOAM RUBBER PLATE DISTANCE WRAP BELT TO FOAM RUBBER PLATE The foam rubber plate is adjusted to the product at wrap-around labelings of cylindrical products. - Page 46 Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Requirements Power and compressed air supply is turned off. No transportation of products. One sample product. Instruction Please adjust the foam rubber plate for wrap-around labeling as follows.
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Page 47: Move Label Position In Transport Direction Forward Or Backward
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Move label position in transport direction forward or backward Fig. 7-5: Delay time Alpha Compact Pos. Description POTENTIOMETER ADJUSTMENT TIME DELAY ALPHA COMPACT The labeling procedure is introduced by the product sensor. If the sensor detects a product, the label application is started after an adjusted delay time. -
Page 48: Correct Adjustments After Labeling Result
Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Correct adjustments after labeling result You are able to draw conclusions from the labeling result to the necessary adjustments. Product with good labeling result Fig. 7-6: Product with good labeling result Error-description: The label is wrinkle-free, exactly and always at the same position on the product. - Page 49 Chapter 7 Adjustment and initial operation of labeling system 32708732 Geset 121 Product with beveled label Fig. 7-8: Product with beveled label Error-description: The label is beveled on the product. Instruction Please correct the labeling result as follows: Step Procedure The inclination of the peeler blade is wrong.
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Page 50: Operation
Chapter 8 Operation 32708732 Geset 121 8. Operation Safety instructions Hazard from actively controlled movements. RISK OF INJURY FROM CRUSHING! The applicator movements are motor-driven by an automatic controller. ̶ Maintain a distance from moving parts. Danger of being pulled in by rotating elements. -
Page 51: Operating- And Display Elements
Chapter 8 Operation 32708732 Geset 121 Operating- and display elements Turn on and off machine The main switch of the machine is located at the switch cabinet’s front. To turn the machine on, turn the main switch to [ON]-position (clockwise). -
Page 52: Turn On Labeling Operation
Chapter 8 Operation 32708732 Geset 121 Turn on labeling operation The automatic operation is used to label products: Requirements Labeling system is turned off. Material rolls at labeling system loaded and threaded. Labeling system is connected to power and compressed air. -
Page 53: Turning Off The System
Chapter 8 Operation 32708732 Geset 121 Turning off the system When turning off the system for several hours, the label web must be removed from the applicator. Turning off the system is used to terminate production operation. The label material running around the deflection rollers is curved which can cause prob- lems with the operation mode. -
Page 54: Putting The System Out Of Service
Chapter 8 Operation 32708732 Geset 121 Putting the system out of service If the system is put out of service longer than 4 weeks, please arrange following steps: Requirements System was turned off like described in chapter “Turning off the system“. -
Page 55: Acknowledge Errors
Chapter 8 Operation 32708732 Geset 121 Acknowledge errors After a failure (e. g. roll end at labeling system), the error has to be acknowledged for a new startup of the labeling system. Requirements Labeling system is turned on. ... -
Page 56: Maintenance
Chapter 9 Maintenance 32708732 Geset 121 9. Maintenance Safety instructions Hazard from direct or indirect contact with voltage- conducting parts. DANGER TO LIFE! ̶ Disconnect the labeling system from the mains voltage before working on it. *² Hazard from residual compressed air in the pneumatic com- ponents. -
Page 57: Inspection- And Maintenance List
Chapter 9 Maintenance 32708732 Geset 121 Inspection- and maintenance list Requirements The labeling station is without power (no electrical power or compressed air) The product is not being transported All maintenance works at the system have to be documented. Due to individual production conditions, discrepancies may arise that render it necessary to correct the mentioned intervals accordingly. -
Page 58: Weekly Servicing (After Approximately 40 Hours Of Operation)
Chapter 9 Maintenance 32708732 Geset 121 Weekly servicing (after approximately 40 hours of operation) Run. Work to be arranged Measurement Test statistic Lubricant Motors: Contamination, Clean cooling webs. exceptional noises Check bearing for noise. Expert Clean all guidings. Contamination Expert Dedust sensors with a smooth cloth or brush. -
Page 59: Annual Servicing (After Approximately 2000 Hours Of Operation)
Chapter 9 Maintenance 32708732 Geset 121 Annual servicing (after approximately 2000 hours of operation) Run. Work to be arranged Measurement Test statistic Lubricant Emergency stop and safety circuit. Function. Arrange visual- and function inspection, document inspection. Electrician Main power supply: check isolation and grounding. -
Page 60: Inspection
Chapter 9 Maintenance 32708732 Geset 121 Inspection Errors and wear can early be perceived and remedied by the inspection before it leads to damages. Requirements The labeling station is without power (no electrical power or compressed air) The product is not being transported Instruction Please arrange the inspection as follows. -
Page 61: Maintenance Light Sensor And Light Barrier
Chapter 9 Maintenance 32708732 Geset 121 Maintenance light sensor and light barrier Safety instructions Unintended system start. HEALTH HAZARD! When cleaning the light sensors and light barriers, it may be triggered an accidentally reaction of the labeling station due to approaching or touching. -
Page 62: Maintenance Instruction Conveying Systems
Chapter 9 Maintenance 32708732 Geset 121 Maintenance instruction conveying systems Safety instructions Danger of being pulled in by rotating elements. HEALTH HAZARD! The check of the web run has to be arranged at running system under load. ̶ Do not stick anything in, on or between the moving parts. -
Page 63: Check Transport Belts
Chapter 9 Maintenance 32708732 Geset 121 Check transport belts Requirements The labeling station is without power (no electrical power) The product is not being transported Instruction Please check the drive belt and the transport belts as follows. Step... -
Page 64: Retensioning The Strap And The Drive Chain
Chapter 9 Maintenance 32708732 Geset 121 Retensioning the strap and the drive chain Fig. 9-1 Retension transport belt The pull-in step of the conveying strap at the drive roller results from friction. To resolve the sliding resistance of the conveying strap that depends on load, a particular tangential force is required at the drive roller. -
Page 65: Belt Run Correction
Chapter 9 Maintenance 32708732 Geset 121 Belt run correction Fig. 9-2 Adjust transport belt Description TRANSPORT DIRECTION DIRECTION IN WHICH THE TRANSPORT BELT RUNS. ADJUSTMENT DIRECTION OF THE DEFLECTION ROLLER TO BELT RUN CORRECTION. All rolls involved in belt run should be equipped possibly parallel exactly right-angled to belt axis. -
Page 66: Exchange Of Rollers
Chapter 9 Maintenance 32708732 Geset 121 Requirements No transportation of products. Emergency stop push-button is unlocked. Labeling station is connected to power and *²compressed air. Labeling station was put into operation (see chapter „Adjustment of labeling station and start-up“). -
Page 67: Clean Drive Belts And Transport Belts
We recommend a frequent cleaning. If the label rests stick strongly, please use the Bluhm Weber label remover article number 21800771. Observe that electrical components do not get wet. -
Page 68: Troubleshooting
Chapter 10 Troubleshooting 32708732 Geset 121 10. Troubleshooting Safety instructions Hazards from actively controlled movements. RISK OF INJURY FROM CRUSHING! The movements of the labeling system are motor-driven by an automatic controller. - Maintain a distance from moving parts. Danger of being pulled in by rotating elements... -
Page 69: Remedy Of Defects
Chapter 10 Troubleshooting 32708732 Geset 121 Remedy of defects In this chapter, possible error causes and their elimination are described. Failures at the Labeling system Failure Cause Remedy Low Label Prewarning The label material runs out. Exchange the label material in due time. -
Page 70: Index
Chapter 11 Index 32708732 Geset 121 11. Index Access ............33 Inspection- and maintenance list ....57 Acknowledge errors ........55 Installation ..........33 Adjust side guidance ......... 40 Label Out ..........11 Adjustment and initial operation of labeling Low Label ..........11 system............ -
Page 71: Ec Declaration Of Conformity
Chapter 12 EC Declaration of conformity 32708732 Geset 121 12. EC Declaration of conformity EG-KONFORMITÄTSERKLÄRUNG EC-DECLARATION OF CONFORMITY DECLARATION DE CONFORMITE CE Weber Marking Systems GmbH Maarweg 33 D-53619 Rheinbreitbach Wir erklären in alleiniger Verantwortung, dass die Maschine: We declare under our sole responsibility that the machine: Nous déclarons sous notre responsabilité...
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